Yes I did noticed before even in retail ships some times your hull will get damaged when fired upon with shields still up. The problem here is slightely different though as i'm testing with shields set on like 6000 or so. And shots will Always somehow penetrate the shield mesh when shot at a certain angle at a certain part of the ship. (and thats something i've not been able to reproduce with any retail ships)
And a shield mesh closer to the ship seems to be getting worse results then one loosely around it.
Well in that case it sounds like it may not be a shield mesh problem after all. Can you upload the POF and table perhaps for testing/checking?
Yeah, i'll work a bit more on the model and test if the problem is still there. If it is i'll throw the .pof up here.